System and apparatus for installation of tile floor

ABSTRACT

A tile floor system and apparatus, and manner of installation, uses ceramic and other rigid tiles, and a rubbery or polymeric mat or array of mats, providing a grid or pattern of receptacles that cooperatively receive and securely hold the tiles, with a removable grout securable between the tiles, so as to present a convincing appearance of a conventionally mortared and grouted tile floor, with the tiles and grout concealing the mats. The system and apparatus can be configured so as to be quickly and easily removed or replaced, Each mat can be configured for receiving one or multiple tiles, and the adjacent mats are joined together in the pattern or grid using suitable connectors, such as disk shaped biscuits receivable in slots along opposing sides of the individual mats.

This application claims the benefit of U.S. Provisional Application No. 61/730,265, filed Nov. 27, 2012.

TECHNICAL FIELD

This invention relates to a system and apparatus for temporary or permanent installation of ceramic and other rigid tiles on an existing floor or other surface, and, more particularly, that resides in a rubbery or polymeric mat system that provides an array or pattern of receptacles that individually cooperatively receive and securely hold rigid tiles, with a removable grout securable between the tiles, so as to present a finished appearance similar to a grouted tile floor, but all or portions of which can be quickly and easily removed or replaced.

BACKGROUND ART

U.S. Provisional Application No. 61/730,265, filed Nov. 27, 2012, is incorporated herein by reference in its entirety.

Installation of rigid tiles, which here is intended to encompass ceramic, porcelain, natural stone, and synthetic tiles, is a time consuming, laborious task. It involves multiple steps and many different types of ancillary materials. It is also costly, and is usually considered to be permanent.

Ceramic and natural and synthetic stone tiles are generally installed on wood sub-floor in the following manner. Install rigid concrete backer board over existing wood sub-floor. This concrete board is to be mortared to the wood sub-floor and then screwed with special fasteners to the sub-floor.

The next phase of the installation process is to lay down a bed of concrete mortar over the concrete board in preparation of laying the tiles. The mortar material is a powder material that has to be mixed to a proper consistency before this step occurs.

The next step involves installing the individual tiles. A straight line is generally drawn down the center of the room before starting this step to ensure that the tile at each end of the room will be cut to the same dimensions. The tiles are laid into the bed of mortar and manufactured rubber spacers are used to create equal spacing between each tile to receive grout in the next step. This step is relatively time consuming due to having to make each tile parallel and level to the tile next to it.

The final part of the installation process is the grouting. Grout material is material that acts as a stabilizer and filler between the tiles. This material generally comes in a cement based powder that is mixed with water to a proper consistency. When it is mixed to proper consistency it is applied over the entire tile floor until it has filled all the cavities between the tiles.

As evident from the numerous steps involved, installation of a natural or synthetic stone or ceramic tile floor is labor intensive and expensive. The materials are heavy. And mortar and grout require skill to mix and apply. Additionally, repair of a broken tile or tiles usually requires breaking the tile and removing the associated grout and mortar, and installation of a new tile or tiles using the above-described steps. Removal of an entire tile floor typically requires demolition of many or all of the tiles. Resultant disadvantages include that installing, repairing, and removing tile floors is messy, and at least installation typically require professional or high do-it-your-self skill levels. These factors also make it difficult and costly to replace outdated floors. Also, because tile floors are considered permanent installations, they are not typically installed for temporary applications, such as for seasonal uses such as around outdoor pools, for patios, and the like, and for display or show purposes such as in trade shows and the like.

Flooring systems utilizing tiles of pressed wood and polymer materials manufactured to have the appearance of stone or ceramic tiles are also known, and can be considered for temporary applications. These flooring systems typically utilize interlocking dovetail or similar joints for connecting the adjacent tiles or rows of tiles. However, the joints typically have a less convincing natural grout appearance, and the materials are often not water proof or even water resistant so they would not be suitable for wet locations such as around outdoor pools, patios, and the like. The tiles are also subject to easy breakage along their edges when assembled, disassembled, and transported.

Therefore, what is sought is a manner of installation of a tile floor system which can be used for both permanent and temporary applications, is suitable for outdoor and other locations where water or moisture may be present, which allow easy and simple removal and replacement of tiles as required or desired, and which can be transported and stored without damage.

SUMMARY OF THE INVENTION

What is disclosed is a tile floor system and apparatus, and manner of installation, which can be used for both permanent and temporary applications, is suitable for outdoor and other locations where water or moisture may be present, which allow easy and simple removal and replacement of tiles as required or desired, and which can be transported and stored without damage.

According to a preferred aspect of the invention, the system and apparatus can utilize ceramic and other rigid tiles, and is usable on an existing floor or other surface. The invention resides in a rubbery or polymeric mat or array of mats, that provides a grid or pattern of receptacles that cooperatively receive and securely hold tiles, with a removable grout securable between the tiles, so as to present a convincing appearance of a conventionally mortared and grouted tile floor, with the tiles and grout concealing the mats.

According to another preferred aspect of the invention, if desired, the system and apparatus can be configured so as to be quickly and easily removed or replaced, e.g., by removal of the grout from between the tiles, lifting of the tiles from the mats, and removing the mats. As a result, the system and apparatus of the invention is removable and reusable and can be transported from one application to another.

As an attendant advantage, a substantial portion of the labor and materials associated with traditional ceramic tile installation, is eliminated.

In one preferred embodiment, each mat is configured for receiving one individual tile, and the adjacent mats are joined together in the pattern or grid using suitable connectors, such as disk shaped biscuits receivable in slots along opposing sides of the individual mats.

In another preferred embodiment, an individual mat or mats including multiple of the receptacles can be joined together in the above described manner.

As another preferred aspect of the invention, the mats and grout of the invention can be manufactured using a rubber or rubber like material such as a resilient synthetic or semi-synthetic polymer, which will allow it to be installed over existing flooring systems, unfinished subfloors, etc.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a mat of a system and apparatus for installation of tile, according to the invention;

FIG. 2 is another perspective view of the mat of FIG. 1, showing a tile installed in a receptacle thereof;

FIG. 3 is a side view of the mat of FIG. 1;

FIG. 4 is a fragmentary side view of aspects of the invention, including two mats of the system holding tiles, and a flexible foam grout therebetween;

FIG. 5 is a top view of aspects of the invention, including an array of the mats holding tiles and flexible form grout therebetween;

FIG. 6A is a fragmentary perspective view of two mats of the invention and a connector for connecting the mats together according to the invention;

FIG. 6B is another fragmentary perspective view of the two mats, showing the connector cooperatively received in a slot in the side of a first of the mats;

FIG. 6C is another fragmentary perspective view of the two mats, connected by the connector which is cooperatively received in a slot in the second of the mats also;

FIG. 7 is a fragmentary side assembly view of two of the mats with tiles installed therein and grout therebetween;

FIG. 8A is a perspective view showing dispensing of a representative strip of grout from a tube; and

FIG. 8B is another perspective view of the strip of grout, detached from the tube.

DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

Referring to the FIGS., wherein a system and apparatus of the invention are shown, apparatus 20 of the invention comprises slightly resilient, rubbery or polymeric mats 26 or array of mats, that provides a grid or pattern of receptacles 28 that individually cooperatively receive and securely hold tiles 22, with strips of a removable synthetic grout 30 securable between the tiles 22, which can present a convincing appearance of a conventionally mortared and grouted tile floor, all or portions of which can be quickly and easily removed or replaced by only a fraction of the labor and materials associated with traditional ceramic tile installation and replacement.

Each mat 26 shown in FIGS. 1-4, 6A and 6B is configured for receiving one individual tile 22, while FIG. 5 shows multiple mats 26 that can be individually joined together, or formed as groups or sets of mats, both of which embodiments can be injection molded, cast, or assembled of sheet material, e.g., using adhesives, welding, or the like. Each mat 26 is the same shape as but marginally larger than the tile 22, and will have a flat base or bottom panel 32 that comprises the lower periphery or bottom of the receptacle 28. The material comprising the base or panel 32 is sufficiently firm to support the tile 22 under normal or anticipated use without cracking the tile when located on a flat surface, and can provide some limited vertical resiliency to provide some cushioning feel when walking or standing on the tile, if desired.

Each mat 26 has an elongate, raised peripheral lip 34 therearound having a longitudinally extending outer surface 36 that defines or is vertically coincident with the outward extent of the base or bottom panel 32 of the mat, and an opposite inner surface 38 bounding and forming the sides of the receptacle 28. The peripheral lip 34 extends upwardly from the bottom sheet or panel 32 by a height less than the thickness of the tile 22 to be received in the receptacle 28, but sufficient for gripping and holding the tile when received in the receptacle.

The opposing portions of the lip 34 on opposite sides of the mat 26 and defining the receptacle 28, in a free state, that is, when not disposed about a tile located in the associated receptacle 28, are preferably spaced apart by dimensions marginally smaller than the corresponding dimensions of the tile 22 to be received in the receptacle, such that the lip 34 will be resiliently stretched about the tile to a small degree, sufficiently for gripping and holding the tile securely in the receptacle. If needed, a suitable adhesive such as a rubber cement may be applied for retaining the tile in the receptacle. The inner surface 38 of this resiliently stretchable peripheral lip 34 can also have a profile shape when viewed from the end that is straight and vertical; straight and tapered; or a dovetail; ribbed; or other specialty shape configured for better or more securely gripping and retaining the tile in the receptacle. In this regard, it has been observed that the edges of some tiles are tapered convergingly toward the top, and the inner surface 38 of the peripheral lips 34 can have a corresponding or matching taper, to facilitate gripping and holding the tile in place. As an alternative, the mats 26 can be formed about the lower region of the tiles 22, such as by casting or thermosetting, e.g., using a polymer with heat shrinking capability, or the like. As still another optional feature, the peripheral edges 40 of the tiles 22 and peripheral lips 34 of the mats 22 can have interlocking features, such as interlocking stepped or dovetail elements.

The outer sides 42 of the mats 26 are configured to abut and be connected or interlocked together, to prevent any significant or large relative movement therebetween when the system is installed. When the mats 26 are abutted together in this manner, the exposed portions of the tiles 22 held by those mats will be held apart, forming a gap or groove 44 between the tiles 22 for receiving the grout 30. The sides 42 of the bases or bottom panels 32 of the mats 26 which also encompass the peripheral lips 34 will extend sidewardly relative to the tiles 22 a distance equal to one-half the width of the gap or groove 44. As a result, two mats 26 abutted together will form the full width gap or groove 44.

According to one preferred manner of connecting or interlocking the mats together, the outer sides 42 of the mats 26 are straight and flat, so as to be positionable in surface-to-surface abutting relation. The abutting outer sides 42 of the mats 22 have outwardly facing opposing slots 46 which are aligned and configured to cooperatively receive and grip flat disk shaped biscuits or connectors 48 insertable therein. These connectors 48 are of a more rigid material compared to the material of the mats 26 themselves, such as a stiff and/or reinforced polymer, and the slots 46 are preferably marginally smaller in extent than the connectors 48 such that when the connectors are inserted into the slots, the adjacent material of the mats will resiliently deform or squeeze in at least one dimension about the connectors for gripping and holding them in the slots. The slots 46 are preferably located at a height so as to be disposed below the receptacles 28 for receiving the tiles 22, so that the tiles will overlay but not contact the connectors 48. At least one of the slots 46 is provided in each outwardly facing side 42 of the mats 26, e.g., at the middle between the opposite ends, although it is contemplated that two or more of the slots 46 can be provided, as desired or required for a particular application.

Referring in particular to FIGS. 6A, 6B and 6C, to connect two adjacent mats 22 together, a connector 48 is pressed into the slot 46 of one mat 22 and aligned with the slot 46 of the other, then the mats are brought together. The tiles 22 can be preinstalled, or installed after laying or installing the mats 26 by aligning with the receptacles 28 and pressing them down to be gripped by the peripheral lips 34, and the floor is ready for the grout 30.

According to another preferred aspect of the invention, the grout 30 is composed of a rubber or rubbery polymer material that installs between the tiles 22 of the adjacent mats 26. Suitable material for the grout 30 can be a foamed rubber or polymer, or a solid of the same material and can be provided in preformed strips or rolls, or dispensed or extruded, e.g., from a tube 50, in a free flow form liquidus solid on-site and cure in-situ substantially conforming to the space into which the material is dispensed, e.g., the groove 44 between two adjacent tiles 22. As a non-limiting example, a preformed grout strip having a sectional shape conforming to the shape of the groove 44 can be used, and can be marginally larger in sectional size than the groove 44 so as to be compressible into the groove for retention therein.

In operation, the grout 30 will function as a substitute for real cement based grout, but will be sufficiently resilient so as to expand and contract sidewardly for maintaining in contact with the tiles 22 for limiting or preventing entry of moisture and contaminants therebetween. The resiliency of the grout 30, with that of the mats 26, can be configured to allow some very limited sliding movement of the mats relative to each other, e.g., for thermal and/or moisture caused expansion and contraction, to reduce stress concentrations on the tiles that could damage them. Additionally, if desired or required, the grout 30 can be quickly and easily removed by pulling, so as to be replaceable, or for removal of the tile floor system.

As an optional aspect of the invention, as noted above in reference to FIG. 5, several of the mats 26 can be provided in a connected or unitary grid, as non-limiting examples, as a linear strip of the receptacles; or as a rectangular or square grid, e.g., a 2 tile×2 tile, 4×4, 2×4, 2×5, 3×5, or other number grid; and can be sufficiently flexible so as to be capable of being provided in a roll and rolled up.

As another option, the grout 30 can include special effects features, such as a line of designs, or LEDs or fiber optic strands for illuminating the grid pattern of the floor system. As another optional feature, the grout strips and peripheral lips 34 of the mats 26 can have interlocking features, such as dovetail joints for holding them together. In this regard, the peripheral lips 34 can include a longitudinally extending, upwardly projecting tab, which will abut when two mats are abutting, and the grout strips can have an inverted U-shape cross-sectional profile forming a longitudinally extending recess for cooperatively receiving the tabs, for retaining the grout strips and holding the mats together. As an advantage, the mats and grout strips are securely interlocked, and the longitudinally extending interface between the tabs of the mats is covered and protected by the grout strip to prevent entry of moisture and other contaminants.

As advantages of the invention, it significantly reduces the labor and expense of installing tile floors by eliminating the need for cement boards and mortar. The rubber mat grid is interlocked together, but can be easily disassembled and removed or replaced. The system is well adapted for both indoor and outdoor applications, and also temporary installations, such as at tradeshows, as patios, pool surrounds, and the like.

The tiles placed within the mats can be made of any of several materials including, but not limited to: natural stone, marble, granite, porcelain, artificial stone or ceramic. Adhesives are not necessary in this tile installation system and are replaced by plastic connectors or biscuit joints which secure each rubber grid mat to one another, forming a cohesive floor which can be easily removed and replaced with alternating decorative tiles.

In light of all the foregoing, it should thus be apparent to those skilled in the art that there has been shown and described a system and apparatus for temporary or permanent installation of ceramic and other rigid tiles according to the teachings of the invention. However, it should also be apparent that, within the principles and scope of the invention, many changes are possible and contemplated, including in the details, materials, and arrangements of parts which have been described and illustrated to explain the nature of the invention. Thus, while the foregoing description and discussion addresses certain preferred embodiments or elements of the invention, it should further be understood that concepts of the invention, as based upon the foregoing description and discussion, may be readily incorporated into or employed in other embodiments and constructions without departing from the scope of the invention. Accordingly, the following claims are intended to protect the invention broadly as well as in the specific form shown, and all changes, modifications, variations, and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention, which is limited only by the claims which follow. 

What is claimed is:
 1. A system for installing a plurality of flat, substantially rigid tiles having a predetermined thickness, on an existing floor or other surface, comprising: a mat or mats configured to be laid on the existing floor or other surface, including receptacles configured to receive and hold the tiles, respectively, each of the receptacles having a bottom bounded and defined by a flat base configured to support the tile received in the receptacle, and sides bounded and defined by a raised peripheral lip extending upwardly from the flat base a predetermined height less than the predetermined thickness of the tiles, the raised peripheral lip being configured to securely hold the tile when received in the receptacle.
 2. The system according to claim 1, wherein the raised peripheral lips bounding the receptacles are configured to be resiliently stretched about the tiles when received in the receptacles, respectively.
 3. The system according to claim 2, wherein the raised peripheral lips each include opposing portions on opposite sides of the receptacles, respectively, the opposing portions in a free state being spaced apart by dimensions marginally smaller than a dimension of the tiles to be received in the receptacles, respectively.
 4. The system according to claim 1, comprising a plurality of the mats interlocked together in abutting side by side relation.
 5. The system according to claim 4, wherein the mats in abutting side by side relation are interlocked together by connectors extending into slots in abutting sides of the mats.
 6. The system according to claim 1, further comprising a grout of a rubber or rubbery polymer, configured to be disposed and retained between adjacent ones of the tiles when received and held in side by side relation in the receptacles of the mat or mats.
 7. The system according to claim 6, wherein the grout comprises a preformed strip or roll.
 8. The system according to claim 6, wherein the grout is of an extruded composition.
 9. The system according to claim 1, wherein the peripheral lips include longitudinally extending, upwardly projecting tabs positioned and configured to abut when two of the mats are placed in side by side abutting relation, and wherein the grout strips have an inverted U-shape cross-sectional profile forming a longitudinally extending recess for cooperatively receiving the abutting tabs, for retaining the grout strips and holding the mats in the abutting relation.
 10. The system according to claim 1, wherein the tiles have opposite edges that are tapered convergingly in an upward direction, and the peripheral lips of the mat or mats have opposing inner surfaces bounding the receptacles, respectively, that are tapered convergingly for gripping and retaining the tiles in the receptacles, respectively.
 11. Apparatus for holding a flat, substantially rigid tile having a predetermined shape and thickness, on an existing floor or other surface, comprising: a mat configured to be laid on the existing floor or other surface, including a receptacle configured to receive and hold the tile, the receptacle having a bottom bounded and defined by a flat base configured to support the tile received in the receptacle, and sides bounded and defined by a raised peripheral lip extending upwardly from the flat base a predetermined height less than the predetermined thickness of the tile, the raised peripheral lip being configured to securely hold the tile when received in the receptacle and supported on the base.
 12. The apparatus according to claim 11, wherein the raised peripheral lip bounding the receptacle is configured to be resiliently stretched about the tile when received in the receptacle.
 13. The apparatus according to claim 12, wherein the raised peripheral lip includes opposing portions on opposite sides of the receptacle, which in a free state are spaced apart by dimensions marginally smaller than a dimension of the tile to be received in the receptacle.
 14. The apparatus according to claim 11, comprising a plurality of the mats interlocked together in abutting side by side relation.
 15. The apparatus according to claim 14, wherein the mats in abutting side by side relation are interlocked together by connectors extending into slots in abutting sides of the mats.
 16. The apparatus according to claim 14, further comprising a grout of a rubber or rubbery polymer configured to be retained between adjacent ones of the tiles when received and held in the receptacles of the mats in abutting side by side relation.
 17. The apparatus according to claim 16, wherein the peripheral lips of the mats in the abutting side by side relation include longitudinally extending, upwardly projecting abutting tabs, and wherein the grout strips have an inverted U-shape cross-sectional profile forming a longitudinally extending recess for cooperatively receiving the abutting tabs, for retaining the grout strips and holding the mats in the abutting side by side relation.
 18. A system holding a plurality of flat, substantially rigid tiles having a predetermined thickness, in side by side relation on an existing floor or other surface, comprising: a mat or mats located on the existing floor or other surface, including a plurality of receptacles in the side by side relation, cooperatively receiving and holding the tiles, respectively, each of the receptacles having a bottom bounded and defined by a flat base supporting the tile received therein, and sides bounded and defined by a raised peripheral lip extending upwardly from the flat base a predetermined height less than the predetermined thickness of the tiles, the raised peripheral lips securely holding the tiles in the receptacles
 19. The system according to claim 18, further comprising a grout of a rubber or rubbery polymer retained between adjacent ones of the tiles.
 20. The system according to claim 19, wherein the peripheral lips of the mat or mats include longitudinally extending, upwardly projecting abutting tabs, and wherein the grout strips have an inverted U-shape cross-sectional profile forming a longitudinally extending recess cooperatively receiving the abutting tabs, retaining the grout strips between the adjacent ones of the tiles. 